Manuals / Multiquip / Household Appliance / Water Pump

Multiquip manual LS400/LS500 PUMP - CONTROL BOX ASSY, Control Box Assy

Models: LS500 LS400

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LS400/LS500 PUMP — CONTROL BOX ASSY.

CONTROL BOX ASSY.

PAGE 138 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

Page 138

Image 138

Multiquip manual LS400/LS500 PUMP - CONTROL BOX ASSY, Control Box Assy

Contents

MODELS LS400/LS500 OPERATION AND PARTS MANUALTHIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES SERIESLS400/LS500 PUMPProposition- PROPOSITION65 Warning 65 WARNING Diesel engine exhaust and some ofPage COMPONENT DRAWINGS LS400/LS500 PUMP -TABLE OF CONTENTSMAYCO LS400/LS500 8-10Ordering parts has never been easier PARTS ORDERING PROCEDURESWhen ordering parts, please supply Choose from three easy optionsSAFETY MESSAGE ALERT SYMBOLS LS400/LS500 PUMP - SAFETY MESSAGE ALERT SYMBOLSHAZARD SYMBOLS DANGERCAUTION - ACCIDENTAL STARTING LS400/LS500 PUMP - SAFETY MESSAGE ALERT SYMBOLSWARNING - ROTATING PARTS CAUTION - OVER-SPEED CONDITIONSGENERAL SAFETY LS400/LS500 PUMP - RULES FOR SAFE OPERATIONLS400/LS500 PUMP - RULES FOR SAFE OPERATION TRANSPORTINGTowing DANGER - AMPUTATION RISK MAINTENANCE SAFETYBATTERY EMERGENCIESPage TABLE 1. PUMP SPECIFICATIONS LS400/LS500 PUMP - SPECIFICATIONSTABLE 2. ENGINE SPECIFICATIONS No. of CylindersFigure 1. Dimensions LS400/LS500 PUMP - DIMENSIONSDIMENSIONS TABLE 3. DIMENSIONSLS400/LS500 PUMP - IMPORTANT HAND SIGNALS Figure 2. Operation Hand SignalsLS400/LS500 PUMP - GENERAL INFORMATION CONCRETE MIX DESIGNLS400/LS500 PUMP - GENERAL INFORMATION REGIONAL DIFFERENCESLS400/LS500 PUMP - HOW IT WORKS Figure 4. Pumping CycleFigure 3. Pumping Cycle LS400/LS500 PUMP - PUMP COMPONENTS Figure 5. Major Pump ComponentsLS400/LS500 PUMP - PUMP COMPONENTS LS400/LS500 PUMP - DIGITAL CONTROL PANEL COMPONENTS Figure 6. Pump Digital Control Panel ComponentsSECONDARY SCREENS Screen LS400/LS500 PUMP - DIGITAL READOUT SCREENPRIMARY SCREEN Screen ScreenLS400/LS500 PUMP - ENGINE COMPONENTS Figure 7. Deutz F4L2011F/BF4L2011 Diesel Engine ComponentsINITIAL SERVICING BEFORE STARTING LS400/LS500 PUMP - INSPECTIONFUEL CHECK Figure 8. Fuel Cap GaugeFigure 10. Engine Oil Dipstick LS400/LS500 PUMP - INSPECTIONENGINE OIL CHECK HYDRAULIC OIL CHECKFigure 13. Hydraulic Oil Filler Hole Figure 14. Filling the Lubrication BoxLS400/LS500 PUMP - INSPECTION LOCATION OF PUMP WARNING - REAR STABILIZER SAFETYLS400/LS500 PUMP - SET-UP REAR STABILIZER JACKS4. Place the Direction Control Switch to the FORWARD position Figure LS400/LS500 PUMP - START-UP PROCEDURESTARTING PROCEDURE Figure 22. Direction Control Switch FORWARDFigure 27. Volume Control WARNING - SAFETY GLASSESFigure 26. Pumping Control Switch LOCAL LS400/LS500 PUMP - OPERATIONCAUTION - HOSE/LINE BLOCKAGE Figure 30. Accumulator Pressure GaugeFigure 32. Hopper Remixer Blades Rotation Figure 31. Hopper Remixer Control LeverFigure 36. Antenna Installation REMOTE CONTROL OPTIONALRadio Remote Control Figure 35. Installing Remote Control ModuleLS400/LS500 PUMP - OPERATION Cable Remote ControlFigure 38. Cable Remote Control WARNING -TRANSPORTING PUMPDOWNHILL PUMPING LS400/LS500 PUMP - PUMPING INFORMATIONREMIXTURES VERTICAL PUMPINGNEW PUMPS LS400/LS500 PUMP - PUMPING INFORMATIONSNAP-JOINT COUPLINGS THE EFFECTS OF HEAT AND EXCESSIVE TIME ON CONCRETECLEARING CONCRETE BLOCKAGE CLEARING THE SYSTEM AFTER MIX SET UPWARNING - HOSE/LINE PRESSURE WARNING - BLOCKAGESCLEARING SHUTTLETUBE BLOCKAGE “REVERSE” PUMPING PROCEDURESHUTTLE TUBE INSPECTION PROCEDURE WARNING - SHUTTLE TUBESLS400/LS500 PUMP - MAINTENANCE PUMP CLEANING THE PUMP AND DELIVERY SYSTEMDANGER - AMPUTATION RISK HYDRAULIC OIL SYSTEM MAINTENANCE LS400/LS500 PUMP - MAINTENANCE PUMPWARNING - ACID CLEANING WARNING - HYDRAULIC OILCAUTION - BATTERY MAINTENANCE SAFETY LS400/LS500 PUMP - MAINTENANCE PUMPBATTERY MAINTENANCE Figure 39. Battery Electrolyte LevelsFigure 40. Cleaning the Lubrication Box CAUTION - SAFETY GUIDELINESCLEANINGTHE LUBRICATION BOX CYLINDER LUBRICATION BOXLS400/LS500 PUMP - MAINTENANCE PUMP WEAR PLATE AND CUTTING RINGreplace the rubber energizer ring 3. When the output volume at the end of the delivery lineLS400/LS500 PUMP - MAINTENANCE PUMP The size and type of aggregate The type of concrete being pumpedDANGER - AMPUTATION RISK Wear Ring installation Wear Plate and Ring Replacement ProcedureWear Plate Installation CAUTION - HYDRAULIC OILTEMPERATUREWHEEL BEARINGS Figure 42. Cylinder Stroke Control Switch JOGFigure 43. Manual Cylinder Jogging Switch EXTENDED STORAGE INSTRUCTIONSTrailer Brakes LS400/LS500 PUMP - MAINTENANCE TRAILERManually Adjusting the Brakes Hydraulic BrakesFigure 47. Adjustable Channel With Pintle Eye Coupler LS400/LS500 PUMP - MAINTENANCE TRAILERAdjustable Channel Figure 48. Wheel Hub Components Wheel Hub AdjustmentTorsion Suspension Danger - Raising the TrailerDANGER - Trailer Inspection WARNING - Trailer ImpactCommon Causes for Loss of Trailer LS400/LS500 PUMP -TRAILER SAFETY GUIDELINESTRAILER SAFETY INFORMATION Trailer Towing GuidelinesDriving Conditions LS400/LS500 PUMP -TRAILER SAFETY GUIDELINESCAUTION - Local Towing Regulations WARNING - Transporting PersonnelTrailer Towing Tips Reporting Safety DefectsInoperable Brakes, Lights or Mirrors LS400/LS500 PUMP -TRAILER SAFETY GUIDELINESFigure 50. Vehicle VIN Tag LS400/LS500 PUMP - TRAILER SAFETY GUIDELINESTrailer VIN Tag Figure 51. VIN Tag LocationTrailer Lighting and Braking Connector Electrical ConnectorSafety Chains Tow VehicleBall Hitch Coupler Figure 52. Ball Hitch Coupler Adjustable TongueCoupler Types WARNING - Hitch Ball Load RatingFigure 53. Ball Hitch Coupling Mechanism WARNING - Defective Hitch BallWARNING - Uncoupled Hitch Ball LS400/LS500 PUMP -TRAILER SAFETY GUIDELINESBreakaway Brake System Attaching Safety ChainWARNING - Safety Chains Rigging Figure 55. Breakaway Brake System Breakaway Cable Surge Brake SystemTIRE SAFETY LS400/LS500 PUMP - TRAILER SAFETY GUIDELINESConnecting Trailer Lights Uncoupling the Ball HitchWARNING - Improper Lug Nut Torque WARNING - Lug Nut LooseningDetermining Load Limit of Trailer WARNING - Tire PressureTire Fundamentals StepDetermining Load Limit of Tow Vehicle Step Figure 57. Standard Tire Sidewall InformationUniform Tire Quality Grading Standards UTQGS LS400/LS500 PUMP -TRAILER SAFETY GUIDELINESTable 6. Speed Rating Tire Repair Tire Safety TipsFigure 58. UTQGS Tire Information Replacing Worn or Damaged TiresWheels, Bearings and Lug Nuts WARNING - Flying ObjectsWheel Rims Lug Nut Torque RequirementsFigure 60. Trailer to Tow Vehicle Wiring Diagram WARNING - Trailer LightsLS400/LS500 PUMP -TRAILER SAFETY GUIDELINES WARNING - HYDRAULIC SYSTEM HAZARD LS400/LS500 PUMP - TROUBLESHOOTING PUMPTABLE 9. PUMP TROUBLESHOOTING DANGER - AMPUTATION RISKLS400/LS500 PUMP - TROUBLESHOOTING PUMP TABLE 9. PUMP TROUBLESHOOTING CONTINUEDDecrease volume control on main LS400/LS500 PUMP - TROUBLESHOOTING PUMPTABLE 9. PUMP TROUBLESHOOTING CONTINUED Engine overloaded when pumpingSYMPTOM LS400/LS500 PUMP -TROUBLESHOOTING ENGINETABLE 10. ENGINE TROUBLESHOOTING POSSIBLE PROBLEMSYMPTOM LS400/LS500 PUMP -TROUBLESHOOTING TRAILER BRAKE SYSTEMTABLE 11. BRAKE SYSTEM TROUBLESHOOTING POSSIBLE PROBLEMSOLUTION LS400/LS500 PUMP - TROUBLESHOOTING ELECTRICALTABLE 12. ELECTRICAL TROUBLESHOOTING PROBABLE CAUSESOLUTION LS400/LS500 PUMP - TROUBLESHOOTING ELECTRICALTABLE 12. ELECTRICAL TROUBLESHOOTING continued PROBABLE CAUSEPROXIMITY SWITCH “B” ALTERNATOR V-BELT PROXIMITY SWITCH “A” Figure 61. Location of Components for Electrical TroubleshootingLS400/LS500 PUMP - TROUBLESHOOTING ELECTRICAL MAIN “A” SOLENOID MAIN “B” SOLENOID SWING SOLENOID UNLOADER SOLENOIDLS400/LS500 PUMP - WIRING DIAGRAM CONTROL BOX MANIFO LDLS400/LS500 PUMP - WIRING DIAGRAM CONTROL BOX F C DE H G A I L K J LS400/LS500 PUMP - WIRING DIAGRAM CONTROL BOX CONNECTIONS TO J3 AND J4 CONNECTORS ONDIGITAL CONTROL BOX LS400 AND LS500 LS400/LS500 PUMP - WIRING DIAGRAM CONTROL BOX C A H DF GLS400/LS500 PUMP - WIRING DIAGRAM HOPPER VIBRATOR Figure 65. Optional Hopper Vibrator Wiring DiagramLS400/LS500 PUMP - HYDRAULIC SYSTEM DIAGRAM Figure 66. Hydraulic System DiagramMANIFOLD LS400/LS500 PUMP - MANIFOLD BLOCK PORTS Figure 67. Manifold Block PortsMANIFOLD BLOCK PORTS APPENDIX - CONCRETE MIX INFORMATION Washed Sand-#200 washAPPENDIX - CONCRETE MIX INFORMATION A.S.T.M. STANDARD SPECIFICATION FOR GRADING AGGREGATEFigure 68-A. SlumpTest 1/3 Full APPENDIX - SLUMPTEST PROCEDUREFigure 68-C. SlumpTest Full-Overflow Figure 68-B. SlumpTest 2/3 FullAPPENDIX - RECOMMENDED SHOTCRETE SYSTEM Figure 69. Recommended Shotcrete SystemNO. PART NO APPENDIX - RECOMMENDED SHOTCRETE SYSTEMRECOMMENDED SHOTCRETE SYSTEM PART NAMEFigure 70. Shotcrete System Accessories APPENDIX - RECOMMENDED SHOTCRETE ACCESSORIESRECOMMENDED SHOTCRETE ACCESSORIES HAS PASSED THROUGH THE ENTIRE HOSE LENGTHPART NAME REMARKSAPPENDIX - RECOMMENDED SHOTCRETE ACCESSORIES EM26107QTY. Column SAMPLE PARTS LISTLS400/LS500 PUMP - EXPLANATION OF CODE IN REMARKS COLUMN NO. ColumnCONCRETE PUMP LS400/LS500 PUMP - SUGGESTED SPARE PARTSLS400/LS500 1 Unit10 800-30-MAYCO LS400/LS500 PUMP - NAMEPLATE AND DECALSUSE THIS DECAL OPTION WHEN 3 HYDRAULIC STABILIZER JACKS ARE INSTALLED 1 PLACE DECAL ON LS400 MODELS ONLY 2 PLACE DECAL ON LS500 MODELS ONLYREMARKS LS400/LS500 PUMP - NAMEPLATE AND DECALSPART NAME OPTION HYD. JACKSLS400/LS500 PUMP - NAMEPLATE AND DECALS REMARKS LS400/LS500 PUMP - NAMEPLATE AND DECALSPART NAME USED ON LS400 MODELSLS400/LS500 PUMP - FRAME ASSY FRAME ASSYREMARKS LS400/LS500 PUMP - FRAME ASSYPART NAME CHAIN, TRAILER HITCH, 3/8 X 40, GRADELS400/LS500 PUMP - AXLE ASSY. RIGHT/LEFT AXLE ASSY. RIGHT/LEFTREMARKS LS400/LS500 PUMP - AXLE ASSY. RIGHT/LEFTPART NAME EM98116LS400/LS500 PUMP - BRAKE LINE ASSY BRAKE LINE ASSY34566 LS400/LS500 PUMP - BRAKE LINE ASSYPART NAME KIT, MAIN BRAKE LINELS400/LS500 PUMP - BRAKE LIGHT ASSY BRAKE LIGHT ASSYHARNESS ASSY. W/RECEPTACLES LS400/LS500 PUMP - BRAKE LIGHT ASSYPART NAME REMARKSLS400/LS500 PUMP -TRAILER HITCH ASSY TRAILER HITCH ASSYLS400/LS500 PUMP -TRAILER HITCH ASSY PART NAMEEM29228 LS400/LS500 PUMP - BATTERY ASSY BATTERY BOX W/ BELT LS400/LS500 PUMP - BATTERY ASSYBATTERY ASSY BATTERY 12V 125ALS400/LS500 PUMP - HOPPER ASSY HOPPER ASSYREMARKS LS400/LS500 PUMP - HOPPER ASSYPART NAME INCLUDES ITEMS W/%LS400/LS500 PUMP - HOPPER ATTACHMENT ASSY HOPPER ATTACHMENT ASSYLS400/LS500 PUMP - HOPPER ATTACHMENT ASSY PART NAMEREMARKS LS400/LS500 PUMP - HOPPER INTERIOR ASSY HOPPER INTERIOR ASSYREMARKS LS400/LS500 PUMP - HOPPER INTERIOR ASSYPART NAME BOLT, COUNTER SUNK 5/8-11 x 3 INLS400/LS500 PUMP - SHUTTLE CYLINDER ASSY SHUTTLE CYLINDER ASSYREMARKS LS400/LS500 PUMP - SHUTTLE CYLINDER ASSYPART NAME INCLUDES ITEMS WLS400/LS500 PUMP - LUBRICATION PISTONS ASSY LUBRICATION PISTONS ASSYREMARKS LS400/LS500 PUMP - LUBRICATION PISTONS ASSYPART NAME BOLT, 3/8 NC X 1.3/4 IN. G5LS400/LS500 PUMP - LUBRICATION PISTONS ASSY LS400/LS500 PUMP - LUBRICATION PISTONS ASSY PART NAMEEM514920 LS400/LS500 PUMP - FUELTANK ASSY FUEL TANK ASSYREMARKS LS400/LS500 PUMP - FUELTANK ASSYPART NAME WASHER, LOCK 5/16 INLS400/LS500 PUMP - HEAT EXCHANGER ASSY HEAT EXCHANGER ASSYREMARKS LS400/LS500 PUMP - HEAT EXCHANGER ASSYPART NAME HEAT EXCHANGER ASSYLS400/LS500 PUMP - ACCUMULATOR ASSY ACCUMULATOR ASSYACCUMULATOR ASSY LS400/LS500 PUMP - ACCUMULATOR ASSYPART NAME ACCUMULATOR TEST/CHARGE KITLS400/LS500 PUMP - REMIXER CONTROL ASSY REMIXER CONTROL ASSYLS400/LS500 PUMP - REMIXER CONTROL ASSY PART NAMEREMARKS LOCATION LS400/LS500 PUMP - LUBRICATION PANELPOSITION LENGTH OF LINESLS400/LS500 PUMP - LUBRICATION PANEL PART NAMELS400/LS500 PUMP - ENGINE COVER ASSY ENGINE COVER ASSYREMARKS LS400/LS500 PUMP - ENGINE COVER ASSYPART NAME EM517737LS400/LS500 PUMP - HYDRAULICTANK ASSY HYDRAULIC TANK ASSYREMARKS LS400/LS500 PUMP - HYDRAULICTANK ASSYPART NAME STRAIGHT MALE ADAPTORLS400/LS500 PUMP - ENGINE ASSY LS-40TD/LS-50TD ENGINE ASSYLS400/LS500 PUMP - ENGINE ASSY PART NAMEREMARKS LS400/LS500 PUMP -THROTTLE ASSY THROTTLE ASSYREMARKS LS400/LS500 PUMP -THROTTLE ASSYPART NAME LOCK WASHER 1/4 INLS400/LS500 PUMP -WATER SEPARATOR ASSY WATER SEPARATOR ASSYREMARKS LS400/LS500 PUMP -WATER SEPARATOR ASSYPART NAME REPLACESLS400/LS500 PUMP - HYD. PUMP ASSY HYDRAULIC PUMP ASSYREMARKS LS400/LS500 PUMP - HYD. PUMP ASSYPART NAME MOTORIZED FLOW CONTROL MANIFOLD ASSYMACHINE LS400/LS500 PUMP - MANIFOLD ASSYFRONT OF MANIFOLD ASSYREMARKS LS400/LS500 PUMP - MANIFOLD ASSYPART NAME MANIFOLD ASSYLS400/LS500 PUMP - CONTROL BOX ASSY CONTROL BOX ASSYLS400/LS500 PUMP - CONTROL BOX ASSY PART NAMEREMARKS LS400/LS500 PUMP - CONTROL BOX HARNESSES ASSY CONTROL BOX HARNESSES ASSYLS400/LS500 PUMP - CONTROL BOX HARNESSES ASSY PART NAMEPOLY FLEX TUBE 1/2 IN. BLACK LS400/LS500 PUMP - REMOTE CONTROL CABLE ASSY REMOTE CONTROL CABLE ASSYREMARKS LS400/LS500 PUMP - REMOTE CONTROL CABLE ASSYPART NAME ADAPTER, CORD GRIP 1/2 INLS400/LS500 PUMP - HYDRAULIC STABILIZER ASSY. OPTIONAL LS400/LS500 PUMP - HYDRAULIC STABILIZER ASSY. OPTIONAL PART NAMEPAYMENT TERMS TERMS AND CONDITIONS OF SALE - PARTSSPECIAL EXPEDITING SERVICE FREIGHT POLICYMAYCO PUMPWARRANTY MECHANICAL DRIVE MODELSHYDRAULIC DRIVE MODELS Service Department HERE’S HOW TO GET HELPPLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING Warranty Department